your making it FAR more complex than it needs to be, open and use Windows Calculator in scientific mode. it has numbering system converters, i.e tick the binary button and put in the binary equivelant of 50, or start at 50 in decimal, and thne convert to binary......
All numbers are really binary, in a PLC or PC anyway, so your just changing how it is presented to the user or manipulation filters.......
ADC has a "Decimal" data type, use that for your numbers, and just keep what the binary is doing in your head, OR, you can use the DATA VIEW window and look at, and change the data view type......
for example if you have a 12 bit number, then its max in decimal would be 4096, or 0-4095 in computer talk.
50 decimal, in binary would be: 110010 (using win calculator).
So, in Mach3 if I send a DECIMAL 50 across the modbus, into a User VARIABLE address in the PLC, the PLC sees the 50 as a Binary number, you DONT have to do anything to it.......
scott